Quilting machine for zig zag stitching

ABSTRACT

In a quilting machine having a sewing assembly that includes at least one row of vertically reciprocated needles for stitching together webs or plies of fabric and interposed batting extending past the needles from respective supply rolls to pinch or take-up rollers mounted on a carriage movable relative to the machine frame, and in which the general directions of the lines of stitching formed by the needles are determined by controlled rotation of the pinch rollers and controlled relative movement of the carriage and sewing assembly in the direction of the needle row; mechanisms are provided for the selectively controlled relative reciprocations of the sewing assembly and carriage in the direction of the needle row and in the direction at right angles thereto, that is, the longitudinal direction of the fabric and batting webs, so that zig-zag stitching can be formed in such lines irrespective of the directions of the latter. In a preferred embodiment, the sewing assembly is arranged in a superstructure which is movable relative to the frame in the direction of the needle row and in the direction at right angles thereto, and the reciprocations in such directions are produced by rotated eccentrics which are selectively connected with the superstructure through transmissions including respective clutches having their engagement controlled by cams, for example, as by the cam-actuation of switches for controlling the energization of clutch-engaging solenoids.

[ Apr. 23, 1974 [57] ABSTRACT In a quilting machine having a sewing assembly that includes at least one row of vertically reciprocated needles for stitching together webs or plies of fabric and interposed batting extending past the needles from respective supply rolls to pinch or take-up rollers mounted on a carriage movable relative to the machine frame, and in which the general directions of the lines of stitching formed by the needles are determined by controlled rotation of the pinch rollers and controlled relative movement of the carriage and sewing assembly in the direction of the needle row; mech- STITCHING Inventors: Leif Gerlach;

of Brooklyn [73] Assignee:

N.Yv [22] Filed: 1972 United States Patent Gerlach et al.

[ QUILTING MACHINE FOR ZIG ZAG irection of the fabric and batting webs, so that zi zag stitching can be formed in such lines irres anisms are provided for the selectively controlled relative reciprocations of the sewing assembly and car,- riage in the direction of the needle row and in the direction at right angles thereto d of the directions of the latter. In a preferred e ment, the sewing assembly is arranged in a su ture which is movable relative to the frame rection of the needle row and in the direction at ri angles thereto, tions are produced by rotated eccentrics which are selectively connected with the superstructure through transmissions including respective clutches havin their engagement controlled by cams, for exam by the cam-actuation of switches for controlling the energization of clutch-engaging solenoids.

16 Claims, 9 Drawing Figures 9 A wfimmmm l m m 1111111 1 51 l/ll/l/ l/ 23 2222222 2 7 l l l l l ll l n R .l l l l l 11ml 5 0H9 n d 2 n u "m n m l S "m m .0 T H b "0 N u f. 0 n e E m: d m m d m "L: m WA n.. M s 5 .ID.. "n" I on C "."t 3. D S "H n u "e" u SE u i 18.... l e .h .n hen" u cT m 0 mo V m m mm mem m um rTooma m a om m .WSKBILHGSML r m MD n m M E 02O99880 e .947766657 H0 m s w w w n I m l 7O7209503 m C l l l 0 5 1 M M 657767698 UIF 280599477 y mn 6007235550 mum m 517916850 WW [[I .l. 23333323 PA 1 QUILTING MACHINE FOR ZIG ZAG STITCHING This invention relates generally to quilting machines, and more particularly is directed to improvements in quilting machines of the type including a sewing assembly having at least one row of vertically reciprocated needles for stitching together websv or plies of fabric and interposed batting which extend past the needles from respective supply rolls to pinch or take-up rollers.

In commercially available quilting machines of the described type, the supply rolls and pinch rollers are mounted on a cam-actuated carriage that is movable relative to the machine frame and sewing assembly in the direction of the needle row, and the rotational movements of the pinch rollers to pull the fabric plies longitudinally past the row of needles and the movements of the carriage in the direction of the needle row, that is, transversely with respect to the direction in which the plies are pulled by the pinch rollers, are coordinated so that each needle of the machine produces a line of stitching having its direction and configuration determined by the described movements, with such configuration being repeated during successive operating cycles of the machine. In the commercially available quilting machines of the described type, the configurations of the lines of stitching formed by the several needles during each operating cycle are limited by reason of the fact that, although the carriage is movable back and forth in directions parallel to the needle row, feed of the fabric plies in their longitudinal direction, that is, normal to the direction of the needle row, can only occur in the forward direction, that is, from the supply rolls toward the pinch rollers. Thus, when the carriage is moved in the direction of the needle row, so that the lines of stitching are directed transversely on the fabric plies, the stitching in such lines cannot be formed of zig-zag stitches. Further, in the commercially available quilting machines, the movements of the carriage in the direction of the needle row are effected by actuating mechanisms that include ratchet wheels driven from the main shaft of the machine and by which respective pattern cams are incrementally rotated to cause displacements of the carriage through cam followers engaging the peripheries of the cams. Such actuating mechanisms are not capable of effecting the rapid reciprocation of the carriage, that is, the stitch-by-stitch back-and-forth movement, required for forming zig-zag stitches in the lines of stitching formed longitudinally on the fabric plies when the latter are fed in the forward direction by rotation of the pinch rollers.

Although it has been proposed, for example, in US. Pat. No. 456,726, to provide a special quilting machine in which the carriage movable parallel to the direction of the needle row is mounted, in turn, on a sub-carriage movable in directions normal to the needle row, and actuating mechanisms are provided to effect the controlled movements of both carriages, such actuating mechanisms again include ratchet wheels incrementally rotating pattern cams from which the movements of the carriages are derived and, thus, are incapable of effecting the rapid, stitch-by-stitch reciprocations that would be required for forming zig-zag stitches in the lines of stitching.

Accordingly, it is an object of this invention to provide a quilting machine of the described character with relatively simple and reliable mechanisms by which lines of stitching in any desired patterns, and constituted at least in part of zig-zag stitches may be formed in the fabrics being quilted.

A more specific object is to provide a quilting machine of the described character in which, in addition to the usual side-to-side relative movements of the carriage and sewing assembly and the rotation of the pinch or feed rollers in the direction to pull the fabric plies from the supply rolls, mechanisms are provided for effecting the selectively controlled relative reciprocations of the sewing assembly and carriage in the direction of the needle row or rows and in the direction at right angles thereto, that is, in the longitudinal direction of the fabric and batting webs or plies so that zigzag stitches can be formed in the lines of stitching produced by the several needles irrespective of the directions of such lines.

In a preferred embodiment of the invention, the sewing assembly is arranged in a superstructure which is movable relative to the frame in the direction of the needle row and in the direction at right angles thereto for effecting the aforesaid reciprocations required for producing the zig-zag stitches, while the directions of the lines of stitching are determined by controlled rotation of the pinch or feed rollers and by the movement of the carriage relative to the frame in the direction of the needle row.

Further, in accordance with a feature of this invention, the relative reciprocations of the sewing assembly and carriage in the direction of the needle row and in the direction at right angles thereto are produced by rotated eccentrics which are selectively connected with the superstructure through transmissions including respective clutches having their selective engagement controlled by cams which preferably actuate switches for controlling the energization of clutch-engaging solenoids.

The above, and other objects, features and advantages of this invention will be apparent in the following detailed description of an illustrative embodiment thereof which is to be read in connection with the accompanying drawings, wherein:

FIG. 1 is a simplified perspective view illustrating those components of a quilting machine necessary for understanding this invention which is embodied therein;

FIG. 2 is a top plan view illustrating mechanisms provided in accordance with this invention for selectively effecting rotation of the pinch rollers, side-to-side movements of the carriage, and reciprocations of the sewing assembly relative to the carriage in the direction of the needle row and in the direction at right angles thereto;

FIG. 3 is a detail plan view showing themanner in which the sewing assembly may be supported on the machine frame for reciprocations relative to the carriage;

FIGS. 4 and 5 are detail sectional views taken along the lines 44 and 55, respectively, of FIG. 2, and illustrating details of the mechanisms by which the sewing assembly is reciprocated in the direction of the needle row and in the direction at right angles thereto, respectively; and

FIGS. 6A, 6B, 6C and 6D are schematic views illustrating examples of the patterns of stitching that can be achieved with quilting machines according to this invention.

Referring to the drawings in detail, and initially to FIG. 1 thereof, it will be seen that a quilting machine of the type to which the present invention is desirably applied comprises a frame 1 1 having a bed 12 and a superstructure 13 mounted thereabove, as hereinafter described, and in which needles 14 arranged in one or more rows are mounted for vertical reciprocation. A carriage 15 is slidably mounted on bed 12 of the frame, for example, in guide grooves in the bed, for side-toside movement relative to frame 11, that is, for movements in, directions parallel to the needle row.

As is usual, the material to be quilted is shown to consist of top and bottom fabric plies unwound from supply rolls l6 and 17, respectively, mounted on carriage 15 at one side of the needle row, for example, at the front thereof as shown, and an interposed layer of batting which is unwound from a supply roll 18. The usual pinch or feed rollers 19,20 and 21 are mounted on carriage 15 at the side of the needle row remote from supply rolls l6 and 17, that is, at the back of the needle row, as shown, and engage the fabric plies with the batting therebetween for controlling the longitudinal feed of the plies, that is, the movements of the plies in directions normal to the needle row. It will be apparent that, between the supply rolls l6 and 17 and the feed or pinch rollers 19,20 and 21, the fabric plies and the interposed batting extend through superstructure 13 so as to be stitched together in the usual manner by the action of the needles 14 when the latter are vertically reciprocated.

Mechanisms 22 for controlling the movements imparted to the material being quilted are provided on frame 11 at one end portion thereof and, as shown on FIG. 2, comprise an electric motor 23 which, through a belt and pulley transmission 24, effects rotation of a main shaft 25 having a hand wheel 26 thereon by which slow manual operation can be effected when setting up the machine. Main shaft 25 enters a gear box 27 provided with suitable gearing to cause the relatively high speed rotation of an output shaft 28 which effects one revolution during each stitch formation and from which the reciprocated needles 14 are driven. For example, as

"shown on FIG. 1, a rock shaft 28a journalled in standards 12a at the back of bed 12 is oscillated in synchronism with the rotation of shaft 28 by a suitable conventionaltransmission (not shown) therebetween. A rock arm 28b is fixed to shaft 280 and connected by a ball and socket joint 280 to a link 28d which is similarly connected to a head [40 carrying needles 14 and being vertically movable in suitable guides in superstructure 13. Thus, needles 14 are vertically reciprocated in response to oscillation of shaft 28a. Gear box 27 further causes the relatively low speed rotation of a cam shaft 29 which effects a single complete revolution during each operating cycle of the quilting machine, that is, during the formation of each stitched pattern to be repeated. Cam shaft 29 is shown to carry the conventional cam 30 for effecting the controlled side-to-side movements of carriage 15, for example, by means of cam follower rollers 31 engaging the periphery of cam 30 at opposed locations and being carried by a slide 32 which is mounted for lateral reciprocation and connected, as by a link 33, with carriage 15.

Also extending from gear box 27 is an output shaft 34 (FIG. 2) from which pinch rollers 19,20 and 21 are selectively driven through a suitable transmission or drive assembly 35. In the illustrated quilting machine, the transmission or drive assembly 35 is shown to include a shaft 36 rotatably supported in bearings 37 and being driven from output shaft 34 by meshing gears 38 and 39 (FIG. 2) respectively secured on shaft 34 and 36. A drive gear 40 is freely rotatable on shaft 36 and is selectively coupled to that shaft by means of a clutch device 41 which includes a driving member 42 keyed or splined on shaft 36 for rotation with the latter. The driving member 42 and gear 40 have confronting annular arrays of raked teeth 43 which are engageable, as shown, to rotate gear 40 with shaft 36 when driving member 42 is displaced axially along shaft 36 toward gear 40. However, when driving member 42 is displaced axially on shaft 36 away from gear 40, teeth 43 are disengaged to permit gear 40 to remain at rest while shaft 36 continues to rotate.

In order to effect axial displacement of driving member 42 into selective engagement with gear 40 or into its neutral or disengaged position, driving member 42 is formed with an external, circumferential groove in which is engaged a roller 44 rotatably mounted at one end of an actuating lever 45. Lever 45 is pivotally mounted intermediate its ends, as at 46 (FIG. 2), on a support bracket 47 which further carries a solenoid 48. The armature 49 of solenoid 48 is connected by a link 50 to the end of lever 45 remote from the roller 44. A spring 51 is shown connected between lever 45 and a bracket 52 to urge lever 45 angularly in the direction opposed to the displacement of the lever effected when solenoid 48 is energized. In drive assembly 35, as shown, spring 51 urges lever 45 in the clockwise direction, as viewed on FIG. 2, to move driving member 42 toward gear 40 and thereby engage teeth 43 for coupling gear 40 to shaft 36. However, when solenoid 48 is energized to retract its armature 49, lever 45 is moved counterclockwise against the force of spring 51, and thereby disengages teeth 43 so that gear 40 is uncoupled from shaft 36.

In the illustrated drive assembly 35, drive gear 40 meshes with a gear 53 on a shaft 54 to rotate the latter, and rotation of shaft 54 is transmitted, as through bevel gears 55 and 56, to a shaft 57 and, from the latter, through successive gears 58,59 and 60 to a shaft 61. The gears 58,59 and 60 may be interchanged to alter the drive ratio between shafts 54 and 61 before operation of the quilting machine is commenced. Shaft 61 is shown to be rotatably coupled, through gears 62 and 63, with a shaft 64 which is shown to be connected, as through universal joints 65 and 66 and an intermediate splined, telescoping shaft assembly 67, to an extension 68 at one end of pinch roller 19. The rotation thus imparted to pinch roller 19 is transmitted to the other pinch rollers 20 and 21 through successive meshing gears 69,70 and 71.

The selective energizing of solenoid 48 is effected through a suitable electric circuit (not shown) that includes a switch 72 (FIG. 2) actuable by a cam 73 mounted on cam shaft 29 for rotation with cam 30. The contour of cam 73 is selected to cause closing of switch 72 and energizing of solenoid 48 only during the portion or portions of each operating cycle when it is desired to halt rotation of pinch rollers 19,20 and 21. In order to hold rollers 19,20 and 21 against inadvertent rotation when solenoid 48 is energized, a ratchet 74 may be either fixed or integral with gear 40 and engageable by a pivotally mounted pawl 75. Pawl 75 is deflected upwardly to free ratchet 74 only when solenoid 48 is deenergized, that is, when pinch or feed rollers are to be rotated. For example, a cam rod 76 connected to lever 45 may extend under pawl 75 to lift the latter off ratchet 74 when lever 45 is in the position shown in FIG. 2, and to permit gravity to move pawl 75 into engagement with ratchet 74 when lever 45 is displaced in response to energizing of solenoid 48.

It will be apparent that, in the quilting machine as described above, the vertically reciprocated needles 14 will form respective lines of stitching which, during each portion of the repeat or operating cycle of the machine when cam 30 holds carriage 13 at rest and cam 73 allows switch 72 to remain open for deenergizing solenoid 48 and thereby causing rotation of pinch or feed rollers 19,20 and 21, extend generally in the longitudinal direction of the plies of fabric and batting, and which, during each portion of the repeat or operating cycle when cam 73 closes switch 72 to halt rotation of the feed rollers and cam 30 moves carriage laterally in one direction or the other, extend in the direction transversely across the plies of fabric and batting. Thus, by suitably shaping the cams 30 and 73, the lines of stitching formed by needles 14 can be made to have successive portions which extend generally transversely and longitudinally on the sewn-together fabric plies and batting.

In order to permit the above described quilting machine 10 to produce zig-zag stitches in the transversely and/or longitudinally extending portions of the lines of stitching formed by needles 14, such machine 10 is further provided, in accordance with this invention, with mechanisms for effecting the selectively controlled relative reciprocations of the sewing assembly, that is the superstructure 13 and needles l4, and the carriage in the direction of the needle row or rows and in the direction at right angles thereto, that is, in the transverse and longitudinal directions on the plies of fabric and batting, with such relative reciprocations occurring at a frequency synchronized with the stitch formation by the reciprocated needles. In the illustrated preferred embodiment, such relative reciprocations are achieved by respective movements of the superstructure 13 relative to the frame 11. As shown particularly in FIG. 3, in order to permit the foregoing movements of superstructure 13 relative to frame 11, the superstructure is mounted on bed 12 of frame 11 by a plurality of mounting assemblies 77 which are disposed at least adjacent the opposite ends of superstructure l3 and also preferably adjacent the middle of the latter.

Each of the mounting assemblies 77 is shown to include a pair of guide rods 78 and 79 extending laterally at the front and back, respectively, of the base 13a of superstructure 13 and being each secured, at its opposite ends, in support blocks 80 suitably fixed on the bed 12 of frame 11. Slides 81 and 82 are respectively slidable along guide rods 78 and 79 and are fixedly secured to the opposite ends of a guide rod 83 which extends longitudinally therebetween, that is, at right angles to the direction of the row of needles in superstructure 13. A slide 84 is longitudinally slidable along guide rod 83 and is suitably secured to the underside of the base 13a of the superstructure. Thus, superstructure 13 is movable relative to bed 12 in the direction at right angles to the needle row, that is, in the longitudinal direction of .the fabric plies, by movement of slides 84 along guide rods 83, and the movement of the superstructure relative to bed 12 in the direction of the needle row, that is, transversely across the fabric plies, is made possible by the movement of slides 81 and 82 along guide rods 78 and 79.

In order to urge superstructure 13 to a centered position, as shown on FIG. 3, the quilting machine 10 is further preferably provided with one or more centering assemblies 85 each of which includes a centering block 86 depending from the underside of superstructure base 13a and being engaged, at its four faces, by right angularly related compression springs 87 which respectively engage abutments 88 projecting upwardly from bed 12. It will be apparent that the four springs 87, which exert balanced forces against block 86, serve to yieldably resist displacements of superstructure 13 in both the transverse and longitudinal directions from the neutral or centered position shown on FIG. 3.

Referring now to FIGS. 2 and 4, it will be seen that the mechanism 89 provided, in accordance with this invention, for effecting reciprocations of superstructure 13 may comprise bevel gears 90 and 91 respectively secured on output shaft 28 and on a shaft 92 rotatable in a bearing support 93 secured on bed 12 so that shaft 92 is arranged at right angles to shaft 28. Meshing bevel gears 90 and 91 are dimensioned to effect rotation of shaft 92 at one-half the speed of shaft 28, that is, to effect a single revolution of shaft 92 in the period required for two revolutions of shaft 28 which corresponds to the formation of two stitches by the needles 14 of the sewing assembly. An adjustable eccentric assembly 94 is mounted on shaft 92 and may include a disk 95 secured to such shaft and formed with an eccentrically located circular recess in which an inner disk 96 (FIG. 4) is adjustably secured, as by a set screw 97 (FIG. 2). A pin 98 projects eccentrically from the inner disk 96 and is connected by a ball and socket joint 99 to one end of an actuating link 100 which extends generally laterally toward the adjacent end of superstructure 13. It is apparent that rotation of eccentric assembly 94 with shaft 92 causes reciprocation of actuating link 100 with the length of the reciprocating stroke being adjustably determined by the position of inner disk 96 within disk 95, that is, by the eccentricity of pin 98 relative to the axis of shaft 92.

The reciprocated actuating link 100 is adapted to be selectively connected with superstructure 13 by means of a clutch assembly 101 which, as shown particularly on FIGS. 2 and 3, may include a clutch element 102 secured to one end of superstructure base 13a and having a recess 103 with chamfered edges opening forwardly for receiving a dog or projection 104 which is formed on the adjacent end of actuting actuating 100. It will be apparent that, when dog 104 is engaged in recess 103, that is, when clutch assembly 101 is engaged, actuating link 100 is connected with superstructure 13 so that the reciprocations of actuating link 100 cause corresponding reciprocations of superstructure 13 in the direction of the needle row, that is, transversely across the fabric plies being stitched. However, when actuating link 100 is deflected forwardly to disengage dog 104 from recess 103, as shown on FIG. 2, actuating link 100 is free to continue its reciprocating movements, while superstructure 13 is urged to its laterally centered position by the springs 87 of the centering assemblies 85.

The disengagement of clutch assembly 100 is effected by a clutch disengaging lever 105 extending laterally in back of actuating link 100 and being pivoted at one end, as at 106, on bed 12. Lever 105 is urged forwardly by a spring 107 bearing against a suitable abutment (not shown) on bed 12, and the end of lever 105 remote from its pivot 106 carries a locking dog 108 which is engageable in a recess 109 having chamfered edges and opening rearwardly in clutch element 102 (FIGS. 2 and 4). It is apparent that, when locking dog 108 on lever 105 engages in recess 109, as shown, superstructure 13 is thereby locked in its laterally centered position. Lever 105 further carries a forwardly directed pin 1 which has its forward end slidably engaged in an elongated groove 111 formed in actuating link 100 (FIG. 4). Pin 100 is longitudinally dimensioned so that, when locking dog 108 on lever 105 is engaged in recess 109 of clutch element 102 under the influence of spring 107 acting on lever 105, pin 110 deflects actuating link 100 in the forward direction for removing its dog or projection 104 from recess 103 of the clutch element. Further, by reason of the slidable engagement of the forward end of pin 110 in elongated groove 111, pin 110 serves to guide actuating link 100 in the longitudinal reciprocations of the latter. In order to effect engagement of clutch assembly 101, an anchor 1 12 formed on actuating link 100 is connected by a rearwardly extending tension spring 113 with the armature 114 of a solenoid 115 suitably mounted on bed 12 (FIG. 2). When solenoid 115 is deenergized, its armature 114 is free to-be extended, as shown, so that spring 113 merely functions to hold actuating link 100 in engagement with pin 1 10 and the force of spring 107 is sufficient to maintain locking dog 108 in engagement with the respective recess 109 while actuating link 100 is forwardly deflected to disengage clutch assembly 101. However, when solenoid 115 is energized, its armature 114 is retracted to exert a rearwardly directed pull on actuating link 100 by way of spring 1 13, and the force exerted by solenoid 115 through spring 113, and which is transmitted to lever 105 through pin 110, is sufficient to overcome the force of spring 107 so that lever 105 is pivoted rearwardly to disengage locking dog 108 from recess 109 and to permit the engagement of dog 104 with recess 103, that is, to engage clutch assembly 101.

The quilting machine 10 according to this invention is further shown to comprise a mechanism 89a for selectively effecting reciprocations of superstructure 13 relative to frame 11 in the fore and aft direction, that is, in the direction at right angles to the needle row, and such mechanism 890 is shown to be substantially simi lar to the previously described mechanism 89. More specifically, the mechanism 89a includes meshing spur gears 90a and 91a respectively secured on shaft 28 and on a parallel shaft 920 which is rotatable in bearing supports 930, with gears 90a and 91a being dimensioned to effect the rotation of shaft 92a at one-half the speed of shaft 28. An adjustable eccentric assembly 94a, which may be identical to the previously described adjustable eccentric assembly 94, is secured on shaft 92a and has its eccentric pin 98a connected by a ball and socket joint 99a with the forward end of a rearwardly directed actuating link 100a (FIGS. 2 and 5). It will be apparent that the actuating link 100a is reciprocated longitudinally, that is, in the fore and aft direction, in response to rotation of eccentric assembly 94a with shaft 92a, and that the reciprocating stroke of link 100a is determined by adjustment of the eccentric assembly.

Actuating link a is guided, in its longitudinal reciprocation, by a pin 110 a projecting from a lever a and having its free end slidably received in a longitudinally elongated groove 111a formed in the rear end portion of link 100a, as shown in broken lines on FIG. 5. The lever 105a is pivoted at 106a on a post 1061; projecting upwardly from bed 12, and lever 105a is urged toward the left, as viewed on FIG. 2, that is, in the direction toward link 100a, by a compression spring 107a bearing against an abutment 10712 which extends upwardly from bed 12. The free end portion of lever 105a carries a locking dog 108a which, in response to the action of spring 107a on lever 105a, is engaged in a recess 109a opening at one side of a clutch element 102a which is formed on the upper end portion of an actuating arm 116 secured on one end of a rock shaft 117 journalled in the standards 12a at the back of frame bed 12.

The clutch element 102a further has a recess 103a with chamfered edges opening at the side thereof remote from recess 109a for receiving a dog or projection 104a formed at the rear end portion of actuating link 100a and which, with the recess 103a defines a clutch assembly 101a for selectively controlling the transmission of the reciprocations of link 100a to superstructure 13. As shown particularly on FIGS. 1 and 2, rocker arms 118 are secured on the opposite end portions of shaft 117 so as to extend upwardly therefrom, and the upper ends of arms 118 are pivotally connected by ball and socket joints 119 to the back ends of links 120 which are directed forwardly and have their forward ends connected by ball and socket joints 121 to the opposite ends of superstructure base 13a.

The selective engagement of clutch assembly 101a is controlled by a solenoid 115a suitably secured on bed 12 and having its armature 114a connected by a tension spring 113a with an anchor 112a on actuating link 100a. When solenoid 115a is deenergized to permit its armature 114a to be extended, as shown (FIG. 2), spring 107a deflects lever 105a toward the left to engage locking lug 108a in recess 109a and further, through pin a, to disengage lug 104a from recess 103a, that is, to disengage clutch assembly 101a, whereby actuating link 100a is free to continue its reciprocation, while shaft 117 is locked against turning in a position that corresponds to the centered position of superstructure 13 in the fore and aft direction, that is, in the direction at right angles to the needle row. However, when solenoid a is energized to retract its armature 1 14a, the resulting force applied to link 1000 by way of spring 113a, and which is transmitted to lever 1050 through pin 110a, is sufficient to overcome the force of spring 107a so that lever 105a is pivoted toward the right, as viewed on FIG. 2, for releasing locking dog 108a from recess 109a and for engaging dog 104a in recess 103a. Upon such engagement of clutch assembly 101a, the reciprocation of actuating link 100a causes corresponding angular oscillations of shaft 117, which oscillations, by way of arms 118 and links 120, cause reciprocations of superstructure 13 in the fore and aft direction.

The selective energizing of solenoids 1 15 and 115a is effected through suitable electric circuits (not shown) that respectively include switches 122 and 122a (FIG. 2) actuable by cams 123 and 123a mounted on cam shaft 29. The contour of cam 123 is selected to cause closing of the associated switch 122 and energizing of solenoid 115 only during the portion or portions of each operating cycle of quilting machine 10 when it is desired to effect lateral reciprocations of superstructure 13, for example, when it is desired to form zig-zag stitches in the lines of stitching being produced by needles 14 in the longitudinal direction of the plies of fabric and batting. Similarly, the contour of cam 123a is selected to cause closing of the associated switch 122a and consequent energizing of solenoid 115a only during the portion or portions of each operating cycle when it is desired to effect fore and aft reciprocations of superstructure 13 for forming zig-zag stitches in the lines of stitching being produced by the needles in the direction transversely across the plies of fabric and batt1ng.

Since needles 14 of the sewing assembly are vertically reciprocated to each complete a single stitch formation during each revolution of shaft 28, and since shafts 92 and 92a and the eccentric assemblies 94 and 94a thereon provided for generating the reciprocating movements of links 100 and 100a are rotated at onehalf the speed of shaft 28, as previously described, it will be apparent that, in effecting either the lateral or fore and aft reciprocations of superstructure 13 for forming zig-zag stitches, the stroke in one direction of each such reciprocation will occur during the formation of one stitch and the return stroke of the reciprocation will occur during the formation of a subsequent stitch. It will also be seen that, when the forming of zigzag stitches is terminated by the deenergizing of either solenoid 115 or solenoid 115a, the springs 87 of the centering assemblies 85 will return superstructure 13 to its centered position where the superstructure will again be locked by engagement of lugs 108 and 108a in the respective recesses 109 and 109a. During the formation of zig-zag stitches in response to reciprocation of superstructure 13 by mechanism 89 or 89a, such reciprocation is effected positively from the respective adjustable eccentric assembly 94 or 94a through the described mechanical connections, and there is no difficulty in effecting such reciprocation in the described timed relation to the stitch formation. This is to be contrasted with the difficulty that would be experienced in effecting the necessary reciprocations of superstructure 13 by way of mechanisms driven from cams on cam shaft 29 and having nodes on such cams respectively corresponding to the reciprocations of the superstructure to be effected during each operating cycle of the quilting machine.

As shown in FIG. 6A, the needles 14 of quilting machine 10 according to this invention can produce lines of stitching S which are directed longitudinally on the pliesof fabric and batting, and which are formed of zigzag stitches along their entire lengths, or along any portions thereof. When producing lines of stitching S as shown on FIG. 6A, the cam 30 is given a circular configuration so as to hold carriage 15 in its centered position and cam 73 is shaped so as to continuously maintain switch 72 in its open condition for deenergizing solenoid 48, and thereby permitting the continuous driving of pinch or feed rollers 19, and 21. Further, cam 1230 is shaped so as to maintain switch 122a continuously in its open condition for deenergizing solenoid 1150, while cam 123 is shaped to effect closing of switch 122 during each portion of the operating cycle when it is desired to form zig-zag stitches in the lines of stitching S. In response to such closing of switch 122 and the consequent energizing of solenoid 115, mechanism 89 effects lateral reciprocation of superstructure 13 for forming the desired zig-zag stitches.

If it is desired that each needle 14 of quilting machine 10 should form a line of stitching S (FIG. 6B) or S" (FIG. 6C) having portions S, extending in the longitudinal direction of the fabric plies with intervening portions 8;, extending transversely on the fabric plies, then cams 30 and 73 are shaped, as described above, to avoid lateral displacement of carriage 15 and to cause rotation of pinch or feed rollers 19,20 and 21 during the formation of the portions S,,, and further to effect the necessary lateral movement of carriage 15 and to cause the energizing of solenoid 48 for halting rotation of the pinch or feed rollers during the formation of each portion S Further, cam' 123 is shaped so that, during the formation of each portion S or during only a part of the formation of each such portion of the line of stitching, as in the case of FIG. 6C, solenoid is energized to result in the lateral reciprocation of superstructure 13 for forming zig-zag stitches in the portion 5 Similarly, during the formation of each portion S or during a part thereof in the case of FIG. 6C, cam 123a is shaped to cause energizing of solenoid 115a so that superstructure 13 is thereby reciprocated in the fore and aft direction for producing the desired zig-zag stitches.

In the described quilting machine 10 all of the needles 14 of the sewing assembly have been assumed to be mounted in a common superstructure 13, from which it follows that all of the needles will simultaneously effect similar movements. However, if desired, a quilting machine according to this invention may be provided with two superstructures each containing one or more rows of vertically reciprocated needles, which may be in a staggered arrangement, and with mechanisms similar to the previously described mechanisms 89 and 89a being provided for effecting independent reciprocations of the two superstructures. With such a modified quilting machine according to this invention, it is possible to produce sewed patterns as shown on FIG. 6D in which adjacent lines of stitching S and S produced by respective needles in different superstructures have staggered portions S and S comprised of zigzag stitches. v

In the quilting machine 10 according to this invention, as described above, the reciprocations of the needles 14 mounted in superstructure 13 relative to carriage 15 for producing the desired zig-zag stitches are made possible by mounting such superstructure 13 for movement relative to frame 11 in the direction of the row of needles l4 and in the direction at right angles thereto, and by providing the mechanisms 89 and 89a for effecting the respective reciprocations of superstructure 13 relative to frame 11. However, it will be apparent that the relative reciprocations of needles l4 and the plies of fabric and interposed batting required for forming the zig-zag stitches can be achieved by securely positioning superstructure 13 with respect to frame 11, and by forming carriage 15 in two parts, that is, a lower part which is slidable laterally on frame 11 and has its gross or relatively large lateral movements controlled by pattern cam 30 for determining the general directions of the lines of stitching, and an upper carriage portion which is movably mounted on the lower carriage portion, for example, by mounting assemblies similar to the previously described mounting assemblies 77. In the foregoing alternative arrangement, the described upper carriage portion would carry the supply rolls 16,17 and 18 and the pinch or feed rollers 19,20 and 21, and reciprocating mechanisms similar to the previously described mechanisms 89 and 89a would be provided between the upper and lower carriage portions for selectively effecting the desired rapid reciprocations necessary for forming the zig-zag stitches.

Although the illustrated quilting machine embodying this invention and the above described modification or alternative arrangement thereof are capable of forming zig-zag stitches in the portions of the lines of stitching extending longitudinally on the plies of fabric and interposed batting, and also in the portions of the lines of stitching extending transversely on the plies of fabric and interposed batting, for example, the portions 8,, on FIGS. 68 and 6C, quilting machines may be provided in accordance with this invention to form zigzag stitches only in the portions of the lines of stitching which extend longitudinally on the plies of fabric and interposed batting, for example, as shown on FIG. 6A and at S, on FIGS. 68 and 6C. In that case, the relative reciprocation of superstructure 13 and the carriage carrying supply rolls 16,17 and 18 and feed rollers 19,20 and 21 need only be effected in the direction of the row of needles 14, for example, as by the mechanism 89.

If desired, quilting machines according to this invention may be adapted to cause the zigzag stitches in all, or in some of the lines of stitching to secure ribbons or cords, as indicated at R on FIG. 6A, to the surface of the fabric plies being stitched together with batting interposed therebetween. In order to achieve the foregoing adaptation, the quilting machine 10 according to this invention may be further provided with a ribbon or cord guide bar 124 (FIG. 1) which extends laterally across carriage in front of the row of needles 14. The guide bar 124 may be vertically slidable on pins 125 projecting upwardly from the opposite ends of carriage 15 and carrying helical springs 126 by which guide bar 124 is urged yieldably downward upon the upper surface of the superposed plies of fabric and interposed batting in advance of needles 14. Further, the undersurface of guide bar 124 may be formed with spaced apart grooves 127 aligned with the respective needles 14 and through which ribbons or cords (not shown on FIG. 1) are fed to the stitching locations of selected needles in the row.

Although illustrative embodiments of the invention and various modifications thereof have been described in detail herein, it is to be understood that the invention is not limited to those precise embodiments and modifications, and that various changes and further modifications may be effected therein by one skilled in the art without departing from the scope or spirit of the invention.

What is claimed is:

1. A quilting machine comprising a frame, a superstructure, at least one row of needles vertically movable in said superstructure, means mounting said superstructure on said frame for movement relative to the latter at least in the direction of said needle row, pinch rollers located behind said row of needles and being rotatable for feeding plies of fabric and interposed batting longitudinally past said needles, a carriage supporting said pinch rollers and being mounted on said frame for movement relative to the latter in said direction of the needle row, a drive means for effecting vertical reciprocation of said needles so that the latter produce respective lines of stitching in said plies of fabric and interposed batting, means for effecting the controlled rotation of said pinch rollers, means for effecting the controlled gross movement of said carriage relative to said frame and superstructure in the direction of said needle row and thereby determining the general directions of said lines of stitching in cooperation with said means for the controlled rotation of the pinch rollers, and means for effecting selectively controlled reciprocation of said superstructure relative to said frame and carriage at least in said direction of the needle row at a frequency which is synchronized with the frequency of said vertical reciprocation of the needles so that two of said vertical reciprocations occur in the period required for each reciprocation of the superstructure relative to the frame and carriage.

2. A quilting machine according to claim 1; in which said means for effecting the selectively controlled reciprocation of said superstructure relative to said frame and carriage in said direction of the needle row includes rotatable eccentric means, means for continuously rotating said eccentric means so as to effect a single complete revolution thereof in the period required for said two vertical reciprocations of the needles, transmission means for converting rotation of said eccentric means into said relative reciprocation of the superstructure and the frame and carriage in said direction of the needle row and including selectively engageable clutch means, and control means for selectively engaging said clutch means.

3. A quilting machine according to claim 2; in which said clutch means, when engaged, connects said transmission means with said superstructure for reciprocating the latter relative to said frame.

4. A quilting machine according to claim 3; further comprising lock means made operative upon disengagement of said clutch means for holding said superstructure against movement relative to said frame in said direction of the needle row.

5. A quilting machine according to claim 1; in which said means mounting the superstructure on the frame also permits movement of said superstructure relative to said frame in the direction at right angles to said needle row; and further comprising means for effecting the selectively controlled reciprocation of said superstructure relative to said frame and carriage in said direction at right angles to said needle row at a frequency which is synchronized with the frequency of said vertical reciprocation of the needles so that two of said vertical reciprocations occur in the period required for each reciprocation of said superstructure relative to said frame and carriage in said direction at right angles to the needle row.

6. A quilting machine according to claim 5; in which each of said means for effecting selectively controlled reciprocation of said superstructure relative to said frame and carriage in said direction of the needle row and in said direction at right angles thereto, respectively, includes rotatable eccentric means, means for continuously rotating said eccentric means so as to effeet a single complete revolution thereof in the period required for said two vertical reciprocations of the needles, transmission means for converting rotation of said eccentric means into said reciprocation of the superstructure relative to the frame and carriage in the respective direction and including selectively engageable clutch means, and control means for selectively engaging said clutch means.

7. A quilting meachine according to claim 6; in which each said clutch means, when engaged, connects the respective transmission means with said superstructure for reciprocating the latter relative to said frame in the respective direction.

8. A quilting machine according to claim 7; further comprising lock means associated with each said transmission means and being made operative upon disengagement of said clutch means of the associated transmission means for holding said superstructure against movement relative to said frame in said respective direction.

9. A quilting machine according to claim 1; in which said means for effecting selectively controlled reciprocation of said superstructure relative to said frame and carriage in said direction of the needle row includes eccentric means rotatable in a plane parallel to said direction of the needle row, means for continuously rotating said eccentric means so as to effect a single complete revolution thereof in the period required for said two vertical reciprocations of the needles, an actuating link connected, at one end, to said eccentric means for continuous reciprocation of said link generally in said direction of the needle row, cooperative clutch elements connected to said superstructure and the other end of said actuating link, respectively, and which are vertically engageable for transmitting said reciprocation of the link to said superstructure, and control means for selectively engaging and disengaging said clutch elements.

10. A quilting machine according to claim 9; in which said control means includes a clutch disengaging member being spring urged against said link to deflect the latter for disengaging said clutch elements, and solenoid means connected with said link and which, when energized, is operative to overcome said spring urged clutch disengaging member for engaging said clutch el-' ements.

11. A quilting machine according to claim 10; further comprising cooperative lock elements connected with said superstructure and said clutch disengaging member, respectively, and which are mutually engageable for holding said superstructure against movement relative to said frame in said direction of the needle row when said clutch disengaging member is spring urged to deflect said link, said lock elements being disengaged upon said engaging of the clutch elements.

12. A quilting machine according to claim 10; in which said means for effecting the controlled rotation of said pinch rollers and the controlled gross movement of said carriage includes a rotated cam shaft and respective pattern cams on said cam shaft, and said control means includes an additional cam on said cam shaft and switch means actuable by said additional cam for controlling the energization of said solenoid means.

13. A quilting machine according to claim 9; in which said superstructure is mounted on said frame for further movement relative to the latter in a second direction at right angles to said needle row; and further comprising second eccentric means rotatable in a plane parallel to said second direction, means for continuously rotating said second eccentric means so as to effect a single complete revolution thereof in the period required for said two vertical reciprocations of the needles, a second actuating link connected, at one end, to said second eccentric means for continuous reciprocation generally in said second direction, second cooperative clutch elements connected to said superstructure and to the other end of said second link, respectively, and which are mutually engageable for transmitting said reciprocation of the second link to said superstructure, and second control means for selectively engaging and disengaging said second clutch elements.

14. A quilting machine according to claim 13; in which said second control means includes a clutch disengaging member being spring urged against said second link to deflect the latter for disengaging said second clutch elements, and solenoid means connected with said second link and which, when energized, is operative to overcome said spring urged clutch disengaging member for engaging said second clutch elements.

15. A quilting machine according to claim 14; further comprising cooperative lock elements connected with said superstructure and said clutch disengaging member, respectively, and which are mutually engageable for holding said superstructure against movement relative to said frame in said second direction when said clutch disengaging member is spring urged to deflect said second link, said lock elements being disengaged upon said engaging of the second clutch elements.

16. A quilting machine according to claim 14; in which said means for effecting the controlled rotation of the pinch rollers and the controlled gross movement of said carriage includes a rotated cam shaft and respective pattern cams on said cam shaft, and said second control means includes an additional cam on said cam shaft and switch means actuable by said additional cam for controlling the energization of said solenoid means. 

1. A quilting machine comprising a frame, a superstructure, at least one row of needles vertically movable in said superstructure, means mounting said superstructure on said frame for movement relative to the latter at least in the direction of said needle row, pinch rollers located behind said row of needles and being rotatable for feeding plies of fabric and interposed batting longitudinally past said needles, a carriage supporting said pinch rollers and being mounted on said frame for movement relative to the latter in said direction of the needle row, a drive means for effecting vertical reciprocation of said needles so that the latter produce respective lines of stitching in said plies of fabric and interposed batting, means for effecting the controlled rotation of said pinch rollers, means for effecting the controlled gross movement of said carriage relative to said frame and superstructure in the direction of said needle row and thereby determining the general directions of said lines of stitching in cooperation with said means for the controlled rotation of the pinch rollers, and means for effecting selectively controlled reciprocation of said superstructure relative to said frame and carriage at least in said direction of the needle row at a frequency which is synchronized with the frequency of said vertical reciprocation of the needles so that two of said vertical reciprocations occur in the period required for each reciprocation of the superstructure relative to the frame and carriage.
 2. A quilting machine according to claim 1; in which said means for effecting the selectively controlled reciprocation of said superstructure relative to said frame and carriage in said direction of the needle row includes rotatable eccentric means, means for continuously rotating said eccentric means so as to effect a single complete revolution thereof in the period required for said two vertical reciprocations of the needles, transmission means for converting rotation of said eccentric means into said relative reciprocation of the superstructure and the frame and carriage in said direction of the needle row and including selectively engageable clutch means, and control means for selectively engaging said clutch means.
 3. A quilting machine according to claim 2; in which said clutch means, when engaged, connects said transmission means with said superstructure for reciprocating the latter relative to said frame.
 4. A quilting machine according to claim 3; further comprising lock means made operative upon disengagement of said clutch means for holding said superstructure against movement relative to said frame in said direction of the needle row.
 5. A quilting machine according to claim 1; in which said means mounting the superstructure on the frame also permits movement of said superstructure relative to said frame in the direction at right angles to said needle row; and further comprising means for effecting the selectively controlled reciprocation of said superstructure relative to said fRame and carriage in said direction at right angles to said needle row at a frequency which is synchronized with the frequency of said vertical reciprocation of the needles so that two of said vertical reciprocations occur in the period required for each reciprocation of said superstructure relative to said frame and carriage in said direction at right angles to the needle row.
 6. A quilting machine according to claim 5; in which each of said means for effecting selectively controlled reciprocation of said superstructure relative to said frame and carriage in said direction of the needle row and in said direction at right angles thereto, respectively, includes rotatable eccentric means, means for continuously rotating said eccentric means so as to effect a single complete revolution thereof in the period required for said two vertical reciprocations of the needles, transmission means for converting rotation of said eccentric means into said reciprocation of the superstructure relative to the frame and carriage in the respective direction and including selectively engageable clutch means, and control means for selectively engaging said clutch means.
 7. A quilting meachine according to claim 6; in which each said clutch means, when engaged, connects the respective transmission means with said superstructure for reciprocating the latter relative to said frame in the respective direction.
 8. A quilting machine according to claim 7; further comprising lock means associated with each said transmission means and being made operative upon disengagement of said clutch means of the associated transmission means for holding said superstructure against movement relative to said frame in said respective direction.
 9. A quilting machine according to claim 1; in which said means for effecting selectively controlled reciprocation of said superstructure relative to said frame and carriage in said direction of the needle row includes eccentric means rotatable in a plane parallel to said direction of the needle row, means for continuously rotating said eccentric means so as to effect a single complete revolution thereof in the period required for said two vertical reciprocations of the needles, an actuating link connected, at one end, to said eccentric means for continuous reciprocation of said link generally in said direction of the needle row, cooperative clutch elements connected to said superstructure and the other end of said actuating link, respectively, and which are vertically engageable for transmitting said reciprocation of the link to said superstructure, and control means for selectively engaging and disengaging said clutch elements.
 10. A quilting machine according to claim 9; in which said control means includes a clutch disengaging member being spring urged against said link to deflect the latter for disengaging said clutch elements, and solenoid means connected with said link and which, when energized, is operative to overcome said spring urged clutch disengaging member for engaging said clutch elements.
 11. A quilting machine according to claim 10; further comprising cooperative lock elements connected with said superstructure and said clutch disengaging member, respectively, and which are mutually engageable for holding said superstructure against movement relative to said frame in said direction of the needle row when said clutch disengaging member is spring urged to deflect said link, said lock elements being disengaged upon said engaging of the clutch elements.
 12. A quilting machine according to claim 10; in which said means for effecting the controlled rotation of said pinch rollers and the controlled gross movement of said carriage includes a rotated cam shaft and respective pattern cams on said cam shaft, and said control means includes an additional cam on said cam shaft and switch means actuable by said additional cam for controlling the energization of said solenoid means.
 13. A quilting machine according to claim 9; in which said supeRstructure is mounted on said frame for further movement relative to the latter in a second direction at right angles to said needle row; and further comprising second eccentric means rotatable in a plane parallel to said second direction, means for continuously rotating said second eccentric means so as to effect a single complete revolution thereof in the period required for said two vertical reciprocations of the needles, a second actuating link connected, at one end, to said second eccentric means for continuous reciprocation generally in said second direction, second cooperative clutch elements connected to said superstructure and to the other end of said second link, respectively, and which are mutually engageable for transmitting said reciprocation of the second link to said superstructure, and second control means for selectively engaging and disengaging said second clutch elements.
 14. A quilting machine according to claim 13; in which said second control means includes a clutch disengaging member being spring urged against said second link to deflect the latter for disengaging said second clutch elements, and solenoid means connected with said second link and which, when energized, is operative to overcome said spring urged clutch disengaging member for engaging said second clutch elements.
 15. A quilting machine according to claim 14; further comprising cooperative lock elements connected with said superstructure and said clutch disengaging member, respectively, and which are mutually engageable for holding said superstructure against movement relative to said frame in said second direction when said clutch disengaging member is spring urged to deflect said second link, said lock elements being disengaged upon said engaging of the second clutch elements.
 16. A quilting machine according to claim 14; in which said means for effecting the controlled rotation of the pinch rollers and the controlled gross movement of said carriage includes a rotated cam shaft and respective pattern cams on said cam shaft, and said second control means includes an additional cam on said cam shaft and switch means actuable by said additional cam for controlling the energization of said solenoid means. 